CN109664584B - 一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品及其制备方法 - Google Patents

一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品及其制备方法 Download PDF

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CN109664584B
CN109664584B CN201811459211.6A CN201811459211A CN109664584B CN 109664584 B CN109664584 B CN 109664584B CN 201811459211 A CN201811459211 A CN 201811459211A CN 109664584 B CN109664584 B CN 109664584B
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陈明进
全敦华
郭永新
吴冬生
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Jinyoung Xiamen Advanced Materials Technology Co Ltd
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Abstract

本发明涉及聚乙烯材料改性技术领域，特别涉及一种一步法滚塑发泡用聚乙烯组合物及其应用方法。组合物包括可交联聚乙烯表层、过渡层和可发泡芯层。可交联聚乙烯表层包括以下原料：聚乙烯混合物100份，交联剂0.1‑2份，交联助剂0.1‑2份，其它助剂0.1‑1份，过渡层为热固性交联聚乙烯回收粉料；可发泡芯层包括以下重量份的原料：聚乙烯混合物100份，交联剂0.1‑1份，交联助剂0.1‑1份，发泡剂1‑15份，发泡助剂0.1‑1份，成核剂1‑8份，其它助剂0.1‑1份。本发明解决了滚塑发泡生产效率低的问题，提高生产效率，交联聚乙烯回收料形成过渡层可以防止外层窜孔，确保外层质量，同时可以回收利用交联聚乙烯废料，具有重要的实际应用价值。

Description

一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品及其制备 方法
技术领域
本发明涉及聚乙烯材料改性技术领域，特别涉及一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品及其制备方法。
背景技术
滚塑制品具有中空的特点，比重较轻，往中空部分填充发泡材料，不仅保持了其比重较轻的特点，而且赋予其良好的隔音、保温性能，市场上应用广泛。目前商业化的主要方法是填充PU发泡材料，但存在发泡芯层与滚塑表层粘附性差，材料成本高等缺点；而采用PE发泡泡芯，为了得到具有光滑表面、致密外层和发泡内层的发泡材料，滚塑发泡经历了间歇滚塑发泡、两步法，多步法等生产方法，不但工艺复杂，生产效率低，还要对模具和设备进行改造。而一步法不需要对模具和设备进行大量改造，而且生产效率高，但对滚塑材料提出更高的要求。
目前一步法滚塑发泡主要是利用发泡树脂和非发泡树脂不同的密度、粉末粒径、熔点等差别使之形成致密外层及发泡芯，但因发泡是一个产生压力的过程，容易因压力的产生对表层出现各种不良影响，成品率较低。
发明内容
为解决上述背景技术中的问题，本发明提供一种一步法滚塑发泡用聚乙烯组合物，包括可交联聚乙烯表层、过渡层和可发泡芯层；
所述可交联聚乙烯表层包括以下重量份的原料：
聚乙烯混合物 100份
交联剂 0.1-2份
交联助剂 0.1-2份
其它助剂 0.1-1份;
所述过渡层为热固性交联聚乙烯，其中，可以采用交联聚乙烯回收粉料作为过渡层；
所述可发泡芯层包括以下重量份的原料：
聚乙烯混合物 100份
交联剂 0.1-1份
交联助剂 0.1-1份
发泡剂 1-15份
发泡助剂 0.1-1份
成核剂 1-8份
其它助剂 0.1-1份。
进一步地，所述交联剂为过氧化二苯甲酰、过氧化二异丙苯、叔丁基过氧化-2-乙基己基碳酸酯、二亚乙基三胺、2,5-二甲基-2,5 二叔丁基过氧化己烷、α,α’双(叔丁基过氧化)-1,-3二异丙苯、双叔丁基过氧化二异丙基苯中的一种或至少两种组合。
进一步地，所述交联助剂为聚三烯丙基异三聚氰酸酯、偶氮二异丁腈、偶氮二异庚腈、氢过氧化异丙苯、氢过氧化特丁基、氢过氧化对孟烷、三羟甲基丙烷三甲基丙烯酸酯中一种或至少两种组合。
进一步地，所述交联剂和交联助剂分别为双叔丁基过氧化二异丙基苯及三羟甲基丙烷三甲基丙烯酸酯，二者比例为1：3～1：1；可以使聚乙烯产生交联，提高聚乙烯熔体强度，改善聚乙烯发泡性能。通过交联剂的作用，表层交联聚乙烯在滚塑过程中会发生交联，由热塑性塑料转变成热固性塑料，提高滚塑过程中表层的强度，防止发泡过程对表层产生压力而使表层厚薄不均。
所述发泡剂为N,N-二亚硝基五亚甲基四胺和偶氮化合物的组合，二者的比例为1：3～1：1。
具体地，本发明采用N,N-二亚硝基五亚甲基四胺和偶氮化合物的组合，因二者具有不同的分解发泡温度，在DSC曲线上表现为有两个放热峰，在发泡过程中存在二次发泡，可延缓聚乙烯发泡过程，降低发泡激烈程度，在交联提高聚乙烯熔体强度的双重作用下，可以使发泡聚乙烯泡孔更加均匀，减少并孔，减少溢气，从而减小发泡过程中对表层产生不均匀的压力导致表层厚薄不均匀，不光滑，甚至窜孔，从而使泡制品表层光滑，厚度均匀。
进一步地，所述偶氮化合物为偶氮二甲酰胺、偶氮二甲酰酯、偶氮二甲酸钡中的一种。
进一步地，所述发泡助剂为有机酸盐、金属氧化物、尿素及脲的衍生物、乙酸胺、有机酸中的一种或至少两种组合。
本发明提供的一步法滚塑发泡用聚乙烯组合物生产工艺步骤包括：
步骤a、先将可交联聚乙烯按比例通过双螺杆挤出机生产后磨成可过40-50目网的粉目；
步骤b、将回收的交联聚乙烯破碎加工到可过40-50目；
步骤c、将交联发泡聚乙烯按比例通过双螺杆挤出机生产后磨粉筛分出20-30目粉末；然后将可交联聚乙烯粉末、交联聚乙烯回料粉末及交联发泡聚乙烯粉末依据产品需求按一定比例投入模具中滚塑成型。
本发明提供的一步法滚塑发泡用聚乙烯组合物中，通过交联剂的作用，表层交联聚乙烯在滚塑过程中会发生交联，由热塑性塑料转变成热固性塑料，提高滚塑过程中表层的强度，防止发泡过程对表层产生压力而使表层厚薄不均；过渡层为热固性交联聚乙烯回收料，防止表层与芯层发泡材料直接接触，在表层发生交联前大量混入，使表层产生泡孔，甚至窜孔；过渡层交联聚乙烯回收料利用，可以解决交联聚乙烯回收难问题。
本发明提供的交联聚乙烯组合物可以一次性投入到模具中滚塑成型，解决滚塑发泡生产效率低的问题，提高生产效率，交联聚乙烯回收料形成过渡层减少表面皮层与发泡芯层接触，可以防止外层窜孔，确保外层质量。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的技术方案进行清楚、完整地描述。显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
本发明提供如下表所示的不同原料比例的实施例和对比例:
表1
Figure 928158DEST_PATH_IMAGE001
表层交联聚乙烯中：所述交联剂为过氧化二苯甲酰；所述交联助剂为聚三烯丙基异三聚氰酸酯；所述其它助剂为抗氧剂和润滑剂按照1：1混合；
发泡芯层发泡聚乙烯中：所述交联剂和交联助剂分别为双叔丁基过氧化二异丙基苯及三羟甲基丙烷三甲基丙烯酸酯；成核剂为碳酸钙；发泡剂为N,N-二亚硝基五亚甲基四胺和偶氮化合物的组合；所述其它助剂为抗氧剂和润滑剂按照1：1混合。
实施例1
表层交联聚乙烯制备：
混合：按表1实施例一配方将各组份加入搅拌器进行搅拌使之混合均匀；
造粒：将混合物加入双螺杆挤出机中进行挤出造粒，挤出料熔体温度控制在130℃以内；
磨粉：将挤出粒料于磨粉机磨粉过40目滤网，得到粉体备用。
过渡层交联聚乙烯回收料处理：
将交联聚乙烯回收料挑选、洗净、干燥于磨粉机磨过40目滤网，得到粉体备用。
发泡芯层材料制备：
混合：按表1配方将各组份加入搅拌器进行搅拌使之混合均匀；
造粒：将混合物加入双螺杆挤出机中进行挤出造粒，挤出料熔体温度控制在130℃以内；
磨粉：将挤出粒料于磨粉机磨粉筛分出20-30目粉末，得到粉体备用。
发泡滚塑制品的制备：
准确称取表层交联粉料400g 过渡层粉料100g 发泡料1000g 混合均匀一次性投入模具中，其中：
滚塑条件：
温度：240℃
时间：24分钟
主副轴转速（RPM）：5/15
风冷开模，所得产品表层厚度均匀，无泡孔，致密光滑，低温（-40℃）落锤强度高。
实施例2
按表1配方，并依据实施例1的步骤制备发泡滚塑制品。
实施例3
按表1配方，并依据实施例1的步骤制备发泡滚塑制品。
对比例1
按表1配方，并依据实施例1的步骤制备发泡滚塑制品。
对比例2
按表1配方，并依据实施例1的步骤制备发泡滚塑制品。
对比例3
按表1配方，并依据实施例1的步骤制备发泡滚塑制品。
将上述实施例和对比例制备的样品进行以下测试，测试结果如表2所示：
测试方法：
发泡倍率=发泡前密度/发泡后密度
低温冲击强度采用滚塑专用方法：ARM30。
表2
测试项目 实施例1 实施例2 实施例3 实施例4 对比例1 对比例2 对比例3
表层厚度 均匀 均匀 均匀 均匀 不均匀 不均匀 较均匀
外光 光滑 光滑 光滑 光滑 局部光滑，有窜孔 局部光滑，有窜孔 光滑
表层界面 致密无泡孔 致密无泡孔 致密无泡孔 致密无泡孔 有大量泡孔 有大量泡孔 表层3分之2有泡孔
低温冲击强度（J） 85 74 82 83 18 14 33
发泡倍率% 5.1 5.2 8.3 10.4 5.1 10.2 10.3
通过上述测试结果可以看出：
通过对比例和实施例及表1的结果可以看出，本发明提供的一步法滚塑发泡用聚乙烯组合物，通过特定的工艺，制备的不同发泡倍率制品表层光滑，厚度均匀，不存在窜孔等不良制品。通过实施例发现，随着发泡倍率的提高，制品的表层质量仍然十分良好，低温冲击强度优良，而对比例无法制备表面厚度均匀的制品，特别随发泡倍率的提高，表面质量更差，存在无量泡孔，而且低温冲击强度很差。
最后应说明的是：以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。

Claims (6)

1.一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品，其特征在于，包括可交联聚乙烯表层、过渡层和可发泡芯层；
所述可交联聚乙烯表层包括以下重量份的原料：
聚乙烯混合物 100 份
交联剂 0.1-2 份
交联助剂 0.1-2 份
其它助剂 0.1-1 份
所述过渡层为热固性交联聚乙烯；其中，可以采用交联聚乙烯回收粉料作为过渡层；
所述可发泡芯层包括以下重量份的原料：
聚乙烯混合物 100 份
交联剂 0.1-1份
交联助剂 0.1-1份
发泡剂 1-15 份
发泡助剂 0.1-1 份
成核剂 1-8 份
其它助剂 0.1-1 份；
所述交联剂和交联助剂分别为双叔丁基过氧化二异丙基苯及三羟甲基丙烷三甲基丙烯酸酯，二者比例为1：3～1：1。
2.根据权利要求1所述的一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品，其特征在于：所述发泡剂为N,N-二亚硝基五亚甲基四胺和偶氮化合物的组合，二者的比例为1：3～1：1。
3.根据权利要求2所述的一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品，其特征在于：所述偶氮化合物为偶氮二甲酰胺、偶氮二甲酸酯、偶氮二甲酸钡中的一种。
4.根据权利要求1所述的一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品，其特征在于：所述发泡助剂为有机酸盐、金属氧化物、尿素及脲的衍生物、有机酸中的一种或至少两种组合。
5.根据权利要求1所述的一种一步法滚塑发泡用聚乙烯制备的发泡滚塑制品，其特征在于：所述其它助剂为润滑剂和抗氧剂。
6.一种如权利要求1-5任一项所述一步法滚塑发泡用聚乙烯制备的发泡滚塑制品的制备方法，其特征在于，包括以下步骤：
表层交联聚乙烯制备:
混合:按配方将各组份加入搅拌器进行搅拌使之混合均匀；
造粒:将混合物加入双螺杆挤出机中进行挤出造粒；
磨粉:将挤出粒料于磨粉机磨粉过滤网，得到粉体备用；
过渡层交联聚乙烯回收料处理：
将交联聚乙烯回收料挑选、洗净、干燥于磨粉机磨过40-50目滤网，得到粉体备用；
发泡芯层材料制备:
混合:按配方将各组份加入搅拌器进行搅拌使之混合均匀:
造粒:将混合物加入双螺杆挤出机中进行挤出造粒，挤出料熔体温度控制在130℃以内;
磨粉:将挤出粒料于磨粉机磨粉筛分出20-30 目粉末，得到粉体备用；
发泡滚塑制品的制备:
然后将可交联聚乙烯粉末、交联聚乙烯回料粉末及交联发泡聚乙烯粉末依据产品需求按一定比例投入模具中滚塑成型，即制得发泡滚塑制品。
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